Process for the reduction in microbial activity in protein product chilled water cooling tanks for increased tank water utility and conservation

ABSTRACT

A process for extending the use of chiller water that is used for cooling food products in food production facilities for an extended period of time of at least two production days and up to seven production days by delivering an initial chemical charge at the beginning of each production day to return the chiller water to the desired antimicrobial solution concentration to provide acceptable antimicrobial control of the chiller water over the extended period of time. The process providing acceptable antimicrobial control in the processing of any protein or non-protein based food products that require batch or continuous chilling as part of the production process. The length of time that the water in a chilled water bath (chiller) may be used may be dramatically and safely increased before the bath is emptied for cleaning, sanitizing and refilling.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit, under 35 U.S.C. 119(e) of U.S.Provisional Application 61/272,708 filed on Oct. 23, 2009, the contentsof which are incorporated herein by reference.

FIELD OF THE INVENTION

This invention relates to a particular process intended for the chillingof protein and non-protein based food products in a water bath whichlowers product temperature, helps control microbial growth, and preparesthe product for further processing and packing. Although the focus ofthis present disclosure is on the use of the invention in a chilledwater bath, the invention's use and application is not limited to thisprocess alone. This invention can also be utilized to control microbialactivity and to extend the usable time between filling and drainingoperations for any soaking, dipping, quenching, rinsing, scalding,washing, cooling, heating, or any other type processing bath in which anon-food product or a food product intended for human consumption isprocessed. The application and use of the disclosed invention is not,therefore, limited only to the chiller process but for the sake ofbrevity, this disclosure will reference only a chilled water process foruse in the rapid chilling of a protein product intended for humanconsumption.

BACKGROUND OF THE INVENTION

The world population has grown to point where mass production of thefoods that we consume is no longer a luxury but a requirement. Localfarmers, providing food and food products directly to the marketplace,cannot meet the demands of modern society. The food supply chain nowincorporates very large, complex farms and high speed and very highvolume processing plants to satisfy the need for mass processing andproduction of food. Maintaining a safe food supply chain relies on thededication of those working in the supply chain, the processing plantsand also on the third party oversight of various Federal agencies whoseregulations support and mandate food safety.

With two major exceptions, the physical process of taking an animal fromthe farm to the consumer has changed very little over time. Theintroduction of refrigeration, and the implementation of variouschemistries to help maintain sanitary conditions and to controlmicrobiology, has given modern food processors an advantage not enjoyedby food producers of a century ago. Refrigeration and chemicalintervention practices have become an integral part of food processingfacility operations. These technologies have enabled the high speed,high volume output of the large processing facilities that could nothave been possible in times past without significant concern forconsumer safety. With large scale and continuous processing methodsbeing employed by large processors of protein products, or any otherproduct that is susceptible to microbiological contamination, theconcern for the control of microbiology and the safety of the foodsupply chain is of paramount importance.

Another concern, as the demand for food products increases, is theimpact on natural resources created by this demand. The ecologicalimpact is directly affected by this growth and therefore new processesmust be developed to reduce the impact any given process has on theenvironment. The ecological impact that a food processing plant has onthe environment is no longer a passing concern but a major part ofoperations and planning. Entire processes are built around the controland conservation of natural resources such as water. Older, outdated andless efficient processes are being replaced at significant cost withmore efficient and less wasteful processes that maximizes the utility ofavailable resources. No longer can a plant operate without concern forthe conservation and sustainability of natural resources.

To insure that the food supply chain in modern society is maintained atthe highest levels of safety for the consumer, the plant's employees,and the overall environment, there are federal agencies that monitor theprocessors operations so that a continually safe food supply is assuredand the environmental impact and utilization of natural resources is assafe and efficient as possible.

Modern food processing methods are scrutinized by government agencies toensure compliance with safe handling and processing guidelines designedto minimize issues of food safety in the supply chain Regulations androutine inspections of systems and processes by Federal agencies such asthe USDA, EPA and OSHA, mandate a government-industry alliance thathelps ensure that every effort is made to deliver the safest for productpossible to the consumer.

Very innovative approaches to the systems and methods used in processingfacilities have been implemented to create profits for industry whilemaintaining low consumer cost of the final product. As new processes aredeveloped, the federal agencies that have jurisdiction over anyparticular process are called upon to review the new approach and toensure that the new innovation meets the current guidelines for safety.The higher the processors output, the higher the risk of microbiologicalcontamination, and therefore the more innovative the processor must beto combat this ever present threat to the food chain safety. As newrisks are found, federal guidelines become more stringent.

Large scale refrigeration systems, used to help control microbial growthin various processing applications, have helped the food processingindustry to remain in compliance with food safety goals. Refrigerationapplications and processes are implemented at various locations in theprocessing operation to ensure maximization of microbiology control andshelf life. Depending on the particular product being processed—beef,pork, poultry and fish for example—and the particular operation takingplace, various methods of achieving this reduction in producttemperature are employed.

In poultry processing for example, submersion in large chilled waterbaths is the allowed and preferred method for the rapid reduction incarcass temperature after evisceration. Other means of accomplishing thereduction in temperature for beef or pork products are utilized and willnot be considered in this disclosure as that they do not currentlyutilize a large chilled water bath for the purpose.

BRIEF DESCRIPTION OF THE RELATED ART

Several patents have been granted which involve the use of PeraceticAcid/Hydrogen Peroxide blends for direct application to food productsintended for human consumption. As well other approved applications arefor hard surface sanitizing. As detailed in U.S. Pat. No. 5,632,676 theuse of PAA (Peracetic Acid) at concentrations of 100 to 2000 parts permillion effectively reduces the bacterial level found on the surface offowl to a level that will not produce disease in humans. In U.S. Pat.No. 6,514,556, the use of a PAA blend with other components is describedwhere this material can be applied to the surface of fowl for thesignificant reduction in microbial activity. Both of these patents areexplicit in detail of the effectiveness of PAA as an effectiveantimicrobial material with U.S. Pat. No. 6,514,556 providing detail onactual applications and methods for applying the chemistry.

The disclosure referenced in U.S. Pat. No. 6,514,556 is not directed atthe specific use of the chemistry for the extension of time between whena tank is filled and when it is drained. Neither patent provides adetailed method for the precise application of a PAA chemistry—includinginjection points, locations with reference to the chiller water flowstream, volume and location of water reuse piping, and injection pointsthat defines a procedure that provides for process water to used for anextended period of time as defined in this patent

Chiller Process

The chiller process, as it is commonly termed in the poultry industry,is designed to provide the fastest and most economical method ofachieving a rapid temperature decrease for high volume processing ofeviscerated product in a continuous operation. According to the latestfederally mandated guidelines for the use of a continuous water chillingoperation in a poultry processing facility, a processor must provide ameans for rapidly chilling a carcass to a temperature below 40° F. tominimize microbial growth and to preserve product quality.

The means by which this initial chill operation is accomplished in largeproduction facilities is by feeding a continual flow of product on abelt conveyor into the lead-in section of a large chilled water tank andensuring that the product is submerged continually, typically with awater temperature set at approximately 34° F.

In one typical method, the process incorporates a large tank fitted witha sectionalized and gated conveyor that provides separate sections wherethe product is loaded. The gates are mounted on a chain-type conveyorand continually move through the chilled water bath with the gatesproviding segregation from one load to another. The gates continuouslypush a load of product through the chilled water bath, from the lead-insection to the lead-out section, at a speed that is designed to provideample dwell time for the intended cooling purpose. Another method ofaccomplishing the same material handling operation is the use of a largediameter auger placed in the chiller tank in lieu of the moving gatesdescribed above. The auger flights determine the volume of product thatcan be loaded in each section and the auger rotational speed as well asthe total length of the tank determines the dwell time the product willbe allowed to remain in the chilled bath.

In typical operations, a processor will provide at least two and as manyas four separate chilled water tanks all connected in series with theproduct being transferred from one tank to another via specializedmaterial handling systems located at each end of the tanks. The separatetanks provide a complete separation of the water volumes to ensure thatas the process continues, the product will be subjected to cleaner andcleaner water.

The material handling systems located in between each tank in the seriessupport and facilitates tank separation and the transfer of product fromone tank to another. Once the product has made a complete traverse fromthe entry to end of a tank, it is removed from the current tank andtransferred over to the next tank in the series.

When eviscerated product enters the first chiller tank system, thecarcass is covered with surface contaminants such as blood, loose fleshmaterial, and fecal matter that may be left on the carcass from upstreamprocesses. These materials are a natural result of the eviscerationprocess and therefore the chilled water tank acts as a surface rinse aswell as a means of cooling the product. The greatest portion of thesesurface contaminants are generally flushed from the surface of theproduct as it traverses the first tank, which usually becomes heavilysoiled as a result.

As part of the chiller tank system, it is also common to design cascadepiping which ties the total number or a portion of the processing tankstogether as far as process water flow is concerned. This practice isdesigned to permit water contained in a downstream or “cleaner” tank tobe delivered to an upstream or relatively more highly soiled tank in afixed and relatively small volume. This ensures that relatively cleanwater from a downstream tank is delivered to a relatively heavily soiledupstream tank, providing a semi fresh water supply to the more heavilysoiled tanks. Process water from the first, or most heavily soiled, tankin the product flow line is allowed to overflow to drain. This watervolume is returned to the process by the supply of potable water throughwhat is typically known as ‘make up water’ piping delivered to varioustanks in the process line.

In typical operations, the water volume in each tank is continuallylowered due to water carryover on the product surface from one tank toanother. This volume of water plus the carryover volume must be suppliedback to the chiller with fresh make up water. A lower volume of makeupwater is allowed as long as an approved filtration means is employed onthe chilling recirculation loop in each tank.

In all chiller applications, the means by which the water temperature ismaintained is by the utilization of a chilled water recirculation loop.This water cooling loop uses a pump and heat exchanger that pulls acertain volume of processing water from the chilled water tank, througha chiller heat exchanger, then back to the tank. This produces a counterflow system that ensures that the lead-out product will be continuallyexposed to the coldest water temperature.

This process is continuous in large processing facilities and istypically run for two shifts of operation. At the end of the last shiftor production day, the typical practice is to completely drain the totalchiller system and send this volume of process water to the processor'swastewater treatment system for treatment and discharge from the plant.The processor must provide a waste water treatment system that canhandle the total volume of water in a single discharge at the close ofthe production day or send it to an approved facility that will treatthe wastewater volume for the facility. The chiller tanks are thenrinsed, cleaned, and sanitized in a very labor intensive operation thattakes place at the close of each production day.

Prior to the next day's production shift start-up, the processor mustrefill all of the chiller tanks with water, allowing ample time to chillthe inlet water down to the processing temperature prior to commencingproduction. Based on the high output demand of the production plants,these chiller tanks and systems may have total water volumes from 60,000gallons of water to as high as 300,000 gallons or higher depending onthe total production volume of the plant.

When considering the cost of cooling the inlet water down from itsinitial temperature to the required processing temperature, it isapparent that a significant spike in the in-house refrigeration systemis seen. By analysis of the total volume of water and its initial inlettemperature, the refrigeration load can be as high 6,250 tons ofrefrigeration for a 300,000 gallon process with an inlet temperature of65° F. and a one hour cool down rate to 35° F.

The total volume of water in the chiller operation makes up a largepercentage of the total volume used in the plant. Moving this amount ofwater into and out of the chiller tanks requires very large pumpingsystems and, therefore, the electrical cost for mass transfer is quitelarge as well.

The requirement that all of the process water must be treated in theplant waste water system also requires a large cost and a very largevolume of water that must be handled in a very short period of time.

Reuse Water Process

The term “reuse” water as it is used within this disclosure and in USDAregulations means water that has been allowed to contact the surface ofraw product with subsequent contact allowed on the surface of downstreamraw product.

The water volume used in a chiller application is in contact with theouter surfaces of raw product and, according to USDA guidelines, thiswater as well as the overall process is considered to be classified as awater reuse process. This classification as determined by the USDArequires that the entire process be made part of the plant HACCP programfor chemical, physical, and microbiology control.

Hazard Analysis and Critical Control Point (HACCP) is a systematic,preventive process that relies on the control of physical, chemical, andbiological hazards rather than finished product inspection as the meansof ensuring food safety. HACCP is used in the food industry to identifypotential food safety hazards so that key production steps, known asCritical Control Points (CCPs) can be monitored to reduce or eliminatethe risk of hazards potentially present. The HACCP system is used in allstages of food production and preparation processes, includingpackaging, distribution, etc.

Based on USDA regulations, water reuse applications must be incompliance with 9 CFR 416.2 (g)(3) These regulations state that waterthat has contacted raw product may be reused for the same purpose orup-stream provided that measures are taken to reduce physical, chemicaland microbiological contamination or adulteration of the product As partof the HAACP program, and as a means to monitor the antimicrobialpotential of the chemistry in a water reuse process, plant operationspersonnel and USDA will pull water samples from particular physicallocations, as well as from product surfaces at various locations withinthe process, to conduct testing for live microbial presence. Thistesting is often referred to as a Total Plate Count, or TPC.

Other processes, such as the scalder operation in a poultry plant forexample, use the same re-circulated or reuse type water circulationsystems, in most cases, and therefore fall into the same USDA guidelinesfor the plant HACCP program.

Chiller Microbial Control

In order to control microbiology in chiller tanks, it is a typicalpractice to add specialized chemistry to the tanks throughout theprocessing day.

Heretofore, the use of chlorine has been the prevalent chemistry ofchoice, but based on the relatively new development of newer and moreenvironmentally friendly chemistries, and problems associated withchlorine being trapped in fats and oils that are contained in theprocess water, chlorine is being replaced as referenced below. In astudy conducted by Dr. Scott Russell, et al, of the University ofGeorgia, and as detailed in several articles referencing the use ofrecycled or reuse water as defined by the USDA, it was found that thechlorinated water tested in commercial chiller process used in a poultryprocessing plant was not providing the efficacy anticipated by theprocessor, even though the chiller water contained approximately 40 ppm(parts per million) of total chlorine and 1 ppm free chlorine. It wasfound that the majority of chlorine in the water was bound to the largeamounts of organic material contained in the recycled water and was,therefore, unavailable to kill Salmonella sp.

When considering the practice of using the total volume of water in thechiller process for one day and taking into account the economic andecological impact this one process has on processing plant operations,it is easy to see why a processor would strive for a much easier andless costly processing system. The processor would greatly benefit fromthe development of ways in which to lower the overall cost of theprocess without adversely affecting product quality while meeting therelevant Federal guidelines set for plant operations.

The invention disclosed herein provides a distinct advantage to theprocessor. This invention enables the extended use of chilled water,scalder water, or any other large volume of water used for processingprotein and non protein-based products that must comply with guidelinesfor reuse water. This invention allows for the extension of time betweenfill and drain operations and complies with all existing USDA FSISrequirements for this type of application. This invention provides asignificant savings in operations as well as a dramatic reduction in theenvironmental impact of sending the chiller operation's extremely largevolume of water through the waste processing system on a daily basis,and therefore would be very advantageous for the processor.

DESCRIPTION OF THE INVENTION

The invention disclosure provided below details the method, equipmentand technology that will enable the food processor to extend the timebetween the initial filling and the subsequent draining of a chilledwater process tank. This invention provides significant savings for theprocessor in electrical cost, waste treatment cost, natural resource useand consumption as well as an overall reduction in sanitation cost. Theinvention will allow for the extended time of use for process chillerwater from the present two shift operation to as many as 5 and up to asmany as 7 days before the total chiller tank volume is drained, cleaned,and sanitized.

It has been found that by properly selecting certain chemistries as wellas providing chemical dosing systems that allow for the precise additionof these chemistries to a process water chiller tank, and providingspecific chemical addition points that are based on the particulardesign of the processor's chiller system, the time that a processor canutilize the full volume of chiller water between fill and drain cyclescan be significantly extended from the present 2 shift time to up to asmany as 7 days and still allow for compliance with USDA regulationsstated in 9 CFR 416.2 (g)(3).

It has been found and tested in a processing facility with oversight bylocal USDA representatives that the time between when a chillerprocessing tank is filled and when it is drained has been extended froma two shift operation to up to seven (7) production days in a row.

The process involves the use of specialized chemistries consisting of aPeracetic Acid (PAA)/Hydrogen Peroxide blend injected into the processtank or chiller recirculation loop in certain areas of the process flowto allow complete disbursement of the active ingredients of thechemistry throughout the system. The means by which the chemistry isadded to the process water volume, along with the particular locationsthat are selected as chemical injection points(based on the processorsparticular chiller system design) are critical to successfully achievingthe goal of extending the length of time water can be used, incompliance with USDA regulations.

Peracetic Acid/Hydrogen Peroxide based chemistries have been evaluatedand have been given regulatory approval for use in certain applicationsin the food processing industries by FSIS. FSIS categorizes thesechemistries in Directive 7120.1 as appropriate for use in “Process waterfor washing, rinsing, cooling, or otherwise for processing meatcarcasses, parts, trim, and organs; and process water applied to poultrycarcasses as a spray, wash, rinse, dip, chiller water, scald water andOLR (On Line Reprocessing) applications.”

It has been found that the process water volume in a chiller tank ortanks can be allowed to be retained in the chill system for usecontinually for up to 7 days by the use of a certain PAA chemistry aswell as by the utilization of the proper dosing systems and chemicalinjection points with chemical concentrations and blends specific to theapplication. Successful compliance with the USDA regulations for theextension of utility time for chilled water has been accomplished withboth a 15% Peracetic Acid/10% Hydrogen Peroxide blend and a 15%Peracetic Acid/5% Hydrogen Peroxide blend.

The concentration of the PAA within the chiller must be between 10 partsper million (ppm) and 230 ppm. Further, it was found that even bettercontrol was established between 20 ppm and 140 ppm, and the best resultsbetween 30 ppm and 120 ppm depending on the product being processed, thesoil loading of the product, the chiller process design and theproduction rate of the process.

The PAA may be injected into the chiller to affect the water useextension time in several ways. One method of injection involves thedelivery of the concentrated chemistry to the discharge location of thechiller make up water supply pipe just prior to its delivery to thechiller tank.

In another successful test, the PAA chemistry was injected directly intothe chiller tank volume at certain locations in the chiller tank thatprovide complete disbursement and distribution of the chemistry as it isdelivered to the tank volume.

It was found that, under certain conditions, it is desirable to treatthe full chilled water tank volume by pre-charging the tank with theproper volumes of PAA chemistry prior to the start of the productionday. This initial filling/charging operation is provided by thespecialized chemical dosing systems and equipment developed specificallyfor the purpose of extending the chilled water utility time.

Typical best results demonstrated that, at the beginning of eachproduction day, a predetermined amount of PAA chemistry is delivered tothe tank by sensing probes that are made part of the chemical dosingequipment developed specifically for this application or bydetermination of the tank concentration by operational personnelconducting manual chemical titration test. This initial chemical charge,no matter how its volume is determined, is delivered to the processtanks automatically through the specialized chemical dosing system.Appropriate dosage concentrations are determined either through in-linesensors or by manual titration processes. The goal of either system isto return the chiller water to the predetermined PAA concentration levelestablished as effective in a particular system. Once the full tankvolume has been provided with the proper chemical dosage to bring thechemical concentration to a level of between 10 parts per million (ppm)and 230 ppm or up to between 20 ppm and 140 ppm or better yet up tobetween 30 ppm and 120 ppm PAA depending on the overall process designand production rate, the tank is released to production for its intendedprocessing application.

For the remainder of the production day, the tank chemical concentrationis maintained at between 10 parts per million (ppm) and 230 ppm or up tobetween 20 ppm and 140 ppm or better yet up to between 30 ppm and 120ppm PAA where this chemical concentration is continually maintained byspecialized chemical concentration sensing probes or probes that aremade part of the chemical dosing equipment developed specifically forthis application or by determination of the tank concentration byoperational personnel conducting manual chemical titration test.

The specialized chemical dosing and control system continually readsprocess, make up, or reuse water flow chemical concentrations andadjusts the delivery of PAA based on the process water needs. At the endof the day the system is shut down during the sanitation shift and thechiller water is left in the body of the chiller. At this time, the redwater system may be cleaned using a ‘clean-in-place’ system (CIP).

After any CIP system has been run, the recirculation pipes arereconnected and the water is re-circulated through the pipes. At thistime, another predetermined amount of PAA may or may not be dispensedinto the chiller. The makeup water is treated in accordance with theprogram that has been established. This same process is followed untilthe end of the production week, at which point the chillers are drained,cleaned, and sanitized.

As an example of the system and process use, the total volume of waterthat can be saved in a given production week of 5 production days andbased on a process that utilizes four chiller tanks each having a totalprocess water volume of 70,000 gallons, the water conservation for thatweek would be 1,050,000 gallons of water.

In addition to the ecological and economic savings seen thought the useof this invention in water conservation, the electrical cost associatedwith moving this large volume of water throughout the process isdrastically reduced.

It can also be demonstrated that there is a very significant reductionin the electrical cost of the refrigeration system, as the utilizationof this invention provides a significantly lower heat load in theprocess water initial chill at the beginning of the production day. Ithas been shown that when using the invention, the residual chilled watertank temperature remains as little as 4° F. above the processingtemperature seen at the end of the production day. Typically, the watertemperature that is delivered to the chiller tanks using potable wateris approximately 65° F. The refrigeration system must chill the totalwater volume down to production temperatures prior to the initiation ofthe processing day. This is a significant cost savings, estimated to beapproximately $500.00 per day for the processor, utilizing the processvolumes referenced in the previous example, and provides otherbeneficial results such as a reduction in refrigeration run times perton per year, thus reducing refrigeration maintenance cost and systembreakdowns. It also allows for faster start up time, thus takingpressure off sanitation crews.

The use of this invention also reduces the cost of sanitation since thechill water tanks are no longer require to be rinsed, cleaned, andsanitized daily, as normally required.

Conclusion

By observation of the cost of operation and the total savings in waterconsumption, electrical cost of pumping and refrigeration, sanitationcost, chemical cost of waste water treatment, and reduction ofmaintenance as a result of the elimination of large water volumehandling in all of the processes associated with the system, it caneasily be shown that the processor, environment and the industry as awhole will benefit greatly by the utilization of this invention.

As a significant means to provide an ecological impact by greatlyreducing the large volume of water used in chiller systems, thisinvention delivers a very beneficial means of significantly reducingprocessing cost while drastically lowering the consumption of a veryprecious natural resource.

1. A process for extending the use of water during the production ofproducts for human consumption comprising: predetermining an amount ofperacetic acid required in a chiller tank system at the start of a firstproduction day to provide a starting concentration of about 10 ppm toabout 230 ppm of peracetic acid in an aqueous solution; delivering aninitial amount of peracetic acid to the chiller tank system to providethe starting concentration of about 10 ppm to about 230 ppm of aqueousperacetic acid solution within the chiller tank system; allowing a firstproduct for human consumption to come in contact with the aqueousperacetic acid solution during a first production day; determiningappropriate concentrations of peracetic acid within the chiller tanksystem during the first production day; adding additional peracetic acidto the chiller tank system to maintain an acceptable concentration ofabout 10 ppm to about 230 ppm of the aqueous peracetic acid solution inthe chiller tank system during the first production day; shutting downproduction using the chiller tank system at the end of the firstproduction day; retaining the remaining aqueous peracetic acid solutionwithin the chiller tank system at a temperature lower than ambienttemperature at the end of the first production day; recharging theaqueous peracetic acid solution retained within the chiller tank systemto the starting concentration of about 10 ppm to about 230 ppm of theaqueous peracetic acid solution at the beginning of a next productionday; shutting down the chiller tank system at the end of the nextproduction day; and draining the chiller tank system; wherein the stepsof shutting down the chiller tank system, retaining the remainingaqueous peracetic acid solution within the chiller tank system, andrecharging the aqueous peracetic acid solution retained within thechiller tank system to the starting concentration at the beginning ofthe next production day, can be repeated to provide up to sevenproduction days before conducting the step of draining the water tanksystem.
 2. The process of claim 1, wherein the step of predeterminingthe amount of peracetic acid required is achieved by sensing probes orchemical titration testing.
 3. The process of claim 1, wherein the stepof recharging the aqueous peracetic acid solution, further comprisespredetermining an amount of peracetic acid required by sensing probes orchemical titration testing to recharge the aqueous acid solutionretained within the chiller tank system to the starting concentration atthe beginning of the next production day, delivering a concentratedamount of peracetic acid to a makeup water supply, and delivering themakeup water supply containing the peracetic acid to the chiller tanksystem.
 4. The process of claim 1, further comprising cleaning thechiller tank system, rinsing the chiller tank system, sanitizing thechiller tank system, or combinations thereof, after the draining step.5. The process of claim 1, wherein the starting concentration of theaqueous peracetic acid solution is between about 10 ppm and about 140ppm at the beginning of at least one of the respective production days.6. A process for extending the use of water during the production ofproducts for human consumption comprising: providing a chiller tanksystem with a process volume of an aqueous antimicrobial interventionsolution, the aqueous antimicrobial intervention solution comprisingperacetic acid at a predetermined initial chemical concentration ofabout 10 ppm to about 230 ppm; allowing a product for human consumptionto come in contact with the aqueous antimicrobial intervention solutionduring a first production day; maintaining an acceptable concentrationof about 10 ppm to about 230 ppm of peracetic acid in the aqueousantimicrobial intervention solution during the first production day;shutting down production using the chiller tank system at the end of thefirst production day; retaining the remaining aqueous antimicrobialintervention solution within the chiller tank system at a temperaturelower than ambient temperature at the end of the first production day;recharging the process volume comprising the aqueous antimicrobialintervention solution retained within the chiller tank system to asecond predetermined chemical concentration of about 10 ppm to about 230ppm of peracetic acid at the beginning of a next production day;allowing a product for human consumption to come in contact with theaqueous antimicrobial intervention solution during the next productionday; maintaining an acceptable concentration of about 10 ppm to about230 ppm of peracetic acid in the aqueous antimicrobial interventionsolution during the next production day; and draining the aqueousantimicrobial intervention solution from the chiller tank system;wherein the steps of shutting down the chiller tank system, retainingthe remaining aqueous antimicrobial intervention solution within thechiller tank system, and recharging the process volume of the aqueousantimicrobial intervention solution in the chiller tank system to thepredetermined chemical concentration of peracetic acid at the beginningof the next production day, can be repeated up to five additional timesto provide up to seven production days before conducting the step ofdraining the aqueous antimicrobial intervention solution from thechiller tank system.
 7. The process of claim 6, wherein thepredetermined initial chemical concentration of peracetic acid at thebeginning of any of the production days is between about 10 ppm andabout 140 ppm.
 8. The process of claim 7, wherein any of the steps ofmaintaining an acceptable concentration of peracetic acid in the aqueousantimicrobial intervention solution during any of the respectiveproduction days is between about 10 ppm and about 140 ppm.
 9. Theprocess of claim 8, wherein any of the steps of maintaining anacceptable concentration of peracetic acid in the aqueous antimicrobialintervention solution during any of the respective production days,further comprises conducting a chemical titration test to determine theconcentration of peracetic acid in the process volume; and addingperacetic acid to the process volume based on a result of the chemicaltitration test to maintain the acceptable concentration of peraceticacid in the aqueous antimicrobial intervention solution.
 10. The processof claim 8, wherein any of the steps of maintaining an acceptableconcentration of peracetic acid in the aqueous antimicrobialintervention solution during any of the respective production days,further comprises using sensors to provide sensor data about a workingconcentration of peracetic acid in the process volume; and addingperacetic acid to the process volume based on the sensor data tomaintain the acceptable concentration of peracetic acid in the aqueousantimicrobial intervention solution.
 11. The process of claim 10,wherein the step of adding peracetic acid to the process volume tomaintain the acceptable concentration of peracetic acid, furthercomprises delivering a concentrated amount of peracetic acid within amakeup water supply to the chiller tank system.
 12. The process of claim6, wherein the acceptable concentration of peracetic acid in the aqueousantimicrobial intervention is maintained between about 10 ppm and 230ppm.
 13. The process of claim 6, wherein the steps of shutting down thechiller tank system, retaining the remaining aqueous antimicrobialintervention solution within the chiller tank system, and recharging theprocess volume of the aqueous antimicrobial intervention solution in thechiller tank system to the predetermined chemical concentration ofperacetic acid, are not repeated such that there are two production daysprovided before conducting the step of draining the aqueousantimicrobial intervention solution from the chiller tank system. 14.The process of claim 6, wherein the steps of shutting down the chillertank system, retaining the remaining aqueous antimicrobial interventionsolution within the chiller tank system, and recharging the processvolume of the aqueous antimicrobial intervention solution in the chillertank system to the predetermined chemical concentration of peraceticacid at the beginning of the next production day, are each repeated atleast once and up to five additional times such that there are at leastthree production days and up to seven production days provided beforeconducting the step of draining the aqueous antimicrobial interventionsolution from the chiller tank system.
 15. The process of claim 14,further comprising allowing a product for human consumption to come incontact with the aqueous antimicrobial intervention solution during eachof the respective production days, wherein the products for humanconsumption for each of the respective production days are not the sameproduct but are the same type of product.
 16. The process of claim 14,further comprising maintaining an acceptable concentration between about10 ppm and about 140 ppm of peracetic acid in the aqueous antimicrobialintervention solution during each of the respective production days. 17.The process of claim 6, wherein the step of recharging the processvolume, further comprises predetermining an amount of peracetic acidrequired by sensing probes or chemical titration testing to recharge theprocess volume retained within the chiller tank system to thepredetermined initial chemical concentration at the beginning of thenext production day, delivering a concentrated amount of peracetic acidto a makeup water supply, and delivering the makeup water supplycontaining the peracetic acid to the chiller tank system.
 18. A processfor extending the use of water during the production of one or moreproducts for human consumption comprising: providing a startingconcentration of about 10 ppm to about 230 ppm of an aqueous peraceticacid solution within a chiller tank system during a first productionday; placing a product for human consumption into the aqueous peraceticacid solution during a first production day; removing the product forhuman consumption from the aqueous peracetic acid solution during thefirst production day; shutting down production using the chiller tanksystem at the end of the first production day; retaining the remainingaqueous peracetic acid solution within the chiller tank system at atemperature lower than ambient temperature after shutting down thechiller tank system at the end of the first production day; rechargingthe aqueous peracetic acid solution retained within the chiller tanksystem to the starting concentration of about 10 ppm to about 230 ppm ofaqueous peracetic acid solution within the chiller tank system at thebeginning of a next production day; placing a product for humanconsumption into the aqueous peracetic acid solution during a nextproduction day; removing the product for human consumption from theaqueous peracetic acid solution during the next production day; shuttingdown the chiller tank system at the end of the next production day; anddraining the chiller tank system; wherein the steps of shutting down thechiller tank system, retaining the remaining aqueous peracetic acidsolution within the chiller tank system, and recharging the aqueousperacetic acid solution retained within the chiller tank system to thestarting concentration at the beginning of the next production day, canbe repeated to provide up to seven production days before conducting thestep of draining the chiller tank system.
 19. The process of claim 18,wherein the steps of shutting down the chiller tank system, retainingthe remaining aqueous antimicrobial intervention solution within thechiller tank system, and recharging the process volume of the aqueousantimicrobial intervention solution in the chiller tank system to thepredetermined chemical concentration of peracetic acid at the beginningof the next production day, are each repeated at least once and up tofive times such that there are at least three production days and up toseven production days provided before conducting the step of drainingthe chiller tank system.
 20. The process of claim 19, further comprisingmaintaining an acceptable concentration of about 10 ppm to about 230 ppmof peracetic acid in the aqueous antimicrobial intervention solutionduring each of the respective production days.